O-Ring Fix Write-up - E-Code Bixenon's & B6S4 Bixenon's

[JJPA4SE]

Seems like there are random bits of info everywhere but not a complete how to...

Total Time:
5-15 Min.

Tools Needed:
T30 Torx to remove Headlight
T20 Torx to remove Top Gear Assembly
Phillips or 6mm Allen Key to turn adjustment screw
Blue Painters Tape (If you want..)

1. Remove Light from car. I put blue painters tape on the bumper under the light so the bumper doesn't get scratched.

2. Identify Location


3. Unscrew (T20 Torx) screw & Remove Top Gear Assembly


4. Turn Light Upside Down and pull out Gear Shaft (So dirt does not go into the housing). Wipe dirt from around opening while upside down...


5. Remove Old O-Ring and Install New O-Ring on Gear Shaft...


6. Reinstall Gear Shaft with New O-Ring... Some other post's recommend putting Graphite Lube on O-Ring at this time. I have not done this and they seem to be working OK.


7. Reinstall Top Gear Assembly (T20 Torx)... same as Step 3

8. **Optional** Carefully Turn Adjustment Screw both Left and Right to make sure it's in good. Make sure to leave adjustment screw in same place as before so height of light is not changed. Final tweaks may be needed anyways once lights are reinstalled anyways.

9. Cleanup and reinstall Headlights!!


Good Luck and preform fix at your own risk. Be careful not to break anything, it wont be my fault...

[Tgr_Clw]

Awesome write up. Thank you.

[1 sick s4]

what size is the o-ring. can i buy it at a department store.

[Raus]

Nice write-up, thanks.

Are there any other spots bi-xenons leak from? I taped up the whole side over the adjusting gear with aluminum tape and I still get condensation in one headlight when I wash the car.

[JJPA4SE]

what size is the o-ring. can i buy it at a department store.

see below...

Nice write-up, thanks.

Are there any other spots bi-xenons leak from? I taped up the whole side over the adjusting gear with aluminum tape and I still get condensation in one headlight when I wash the car.

I have not heard of any other locations. I tried the tape fix and it didn't work for me. I believe people have had the most success is with the O-Rings.

[europaisch]

Bump for this write up.

I bought my new O-rings from JJPA4ASE and followed the write-up. Everything works perfect now. No more fog!

[SuperAvant]

Can we get the o-ring size??? Really would like to pick it up on my way home tonight

[younga4]

We appreciate you!

[vinny.dtw]

#6 o-ring (7/24" OD x 5/16" ID)

Did this for like a year, and it hasnt fogged up at all

[Fade2Black]

I did this today took me about 10 min.

Thanks

[reapersa4]

1. take your o-ring to your local parts store, match it up and buy one size larger.

2. use rubber grease on the o-ring before re-installing the shaft in the housing.

[Duchenbagen]

#6 o-ring (7/24" OD x 5/16" ID)

Did this for like a year, and it hasnt fogged up at all

Wrong. So here is the correct info.

Danco #6 7/16" OD and 5/16" ID. Stock #96723

You can find these at Home Depot in the plumbing aisle.

[layzie]

^ correct

[DreDay]

Figured I'd share that I did this mod last night. Thanks for the write up, and thanks duchenbagen for the correct o ring size. it was easy to find. no we wait for some rain haha well hopefully snow where I am and because I'm a snowboarder :-)

[diagnosticator]

As the original discoverer and developer of the famous "O" Ring Fix, I recommend flooding the headlight areas with a garden hose after reinstalling the headlights, to prove the fix has been installed correctly, and that the water leak into the housings has been fixed permanently.

[ilko]

Well, after searching through Home Depot and Lowe's and not being able to find the exact O-ring, I ended up doing something else... I used thread seal tape (or teflon tape as it's also known). I pulled the original O-ring about 1/2" down from where it originally sits, then wrapped the spot with 3 layers of teflon tape and then reinserted the O-ring. It seals it nice and tight. No more leaks, no more condensation. YMMV.

[diagnosticator]

Inspired work around! Congrats for your success.

[Time4Audi]

THANK YOU for this!

[JoshDub]

Now that I fixed this I feel bad for all of the other unsuspecting B6 drivers around my area.

[KingChar90]

Thanks so much for all this wonderful information. You saved me $350 + labor because I thought I was going to have to replace the headlights entirely! That NJ dealer can suck it!

Go Audizine!

[wolfsburged]

Does this apply to the non-HID/standard halogen lamps as well? I have the standard halogens and have excessive condensation inside both. Do these also have the o-ring issue?

[old guy]

Does this apply to the non-HID/standard halogen lamps as well? I have the standard halogens and have excessive condensation inside both. Do these also have the o-ring issue?

Nope. That adjustment is only for the OEM HID housings.

[diagnosticator]

Only the S4 bi-xenon housings use the vertical beam adjuster shaft, so that is the only OEM headlight that the O ring replacement applies.

[MattchuAbs]

Hey! Does this apply to B7s as well? My 06 A4 Avant is really misty inside.

[MattchuAbs]

Nevermind, just saw the last comments. Haha. Any idea on leaky A4 B7 Avant headlights?

[Biged243]

I believe you will have to reseal the lens. There are threads in the b7 forum for it. If you do it you might as well do some other mods to your liking.